Scanned source oriented nanofiber formation

ABSTRACT

Nanofibers are formed using electrospray deposition from microfluidic source. The source is brought close to a surface, and scanned in one embodiment to form oriented or patterned fibers. In one embodiment, the surface has features, such as trenches on a silicon wafer. In further embodiments, the surface is rotated to form patterned nanofibers, such as polymer nanofibers. The nanofibers may be used as a mask to create features, and as a sacrificial layer to create nanochannels.

RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No. 10/951,254, filed Sep. 27, 2004, now U.S. Pat No. 7,537,807 which claims priority from U.S. Provisional Application No. 60/506,214; filed on Sep. 26, 2003; which applications are incorporated herein by reference.

This application is related to U.S. patent application Ser. No. 10/394,757 (entitled Electrospray Emitter for Microfluidic Channel, filed May 21, 2003).

GOVERNMENT FUNDING

The invention described herein was made with U.S. Government support under Grant Number ECS-9876771 awarded by National Science Foundation (NSF)/Nanobiotechnology Center (NBTC). The United States Government has certain rights in the invention.

FIELD OF THE INVENTION

The present invention relates to forming nanofibers, and in particular to forming oriented nanofibers using a scanned source.

BACKGROUND OF THE INVENTION

Nanoscale materials, such as nanowires, nanotubes and nanofibers have gained more attention recently because of their unique electrical, optical and mechanical properties. Fabrication of oriented nanofibers on a planar surface and integration of these nanofibers with microfabricated structures such as electrodes of surface topography are required for application to molecular electronics. Randomly oriented nanofibers with diameters in the range of 50 to 500 nm have been fabricated using electrospinning technology and suggested for use in a wide range of applications such as high performance filters, drug delivery, scaffolds for tissue engineering, optical and electronic applications.

Vertically oriented tubes or metal needles, connected to syringe pumps have normally been used as electrospinning sources. In these systems, a droplet of solution is formed at the exit of a tube with diameter in the range of 300 um to 1 mm. The exit of the capillary tubing is normally directed downward to a counter electrode. A Taylor cone is established at the exit of the capillary tube by applying an electric field. A polymeric solution is extracted from the Taylor cone and electrospun toward the counter electrode surface. The distance between the exit of the capillary tubing and the counter electrode is approximately 5-25 cm with an applied electric field of 1000V/cm to 3000V/cm.

Straight nanofibers with diameters ranging from 100 to 300 nm have been fabricated by electrospinning on an edge of a sharpened rotational disc collector for possible application to molecular electronics. However, this approach does not permit fabricating of nanofibers on a planar surface. Therefore, it is difficult if not impossible to integrate nanofibers with microfabricated structures for such applications.

SUMMARY OF THE INVENTION

Nanofibers are formed on a planar surface using electrospray deposition from a microfluidic source. The source is brought close to a surface, and scanned relative to the surface in one embodiment to form oriented or patterned fibers in desired positions. In one embodiment, the source is an electrospray source, such as a microfabricated tip provides a solution from an electrostatically formed Taylor cone formed on the tip.

In one embodiment, the surface has features, such as trenches on a silicon wafer. In further embodiments, the surface is rotated to form patterned nanofibers, such as polymer nanofibers.

In a further embodiment, polymeric nanofibers are formed by electrospinning a polymeric solution on a moving planar silicon surface with microstructures. The nanofibers are integrated with microfabricated structures.

The nanofibers may be used as etch masks for further processing, and may also be used as sacrificial layers to form rounded channels.

In still further embodiments, colloidal suspensions may be provided in the solution to form nanofibers containing nano spheres or other particles. The tips may be dipped in the solution, or fluidic channels may be coupled to the tips to provide the source for the nanofibers. Distances between source and surface, as well as solution viscosity may be varied to form nanofibers with differing properties.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of an electrospinning system for creating polymer nanofibers according to an example embodiment of the invention.

FIG. 2 is an exploded block view example of a channel with integrated electrospray emitter according to an embodiment of the invention.

FIG. 3 is a representation of a Taylor cone established on a tip of an emitter in FIG. 2 according to an example embodiment of the invention.

FIG. 4 is a block perspective view of an electrospinning system for creating polymer nanofibers on a spinning silicon substrate according to an example embodiment of the invention.

FIG. 5 is a planar view of the silicon substrate of FIG. 4 having features formed thereon.

FIG. 6 is a cross section representation of an example nanofiber crossing multiple trenches.

FIG. 7 is a scanning electron microscope representation of example nanofibers crossing different size trenches.

FIG. 8 is a block representation of an example multi-tip electrospray emitter device.

FIG. 9 is a block representation of an example “Y” shaped channel.

FIGS. 10A, 10B, 10C, 10D, 10E and 10F are block schematic diagrams illustrating formation of a tip according to an example embodiment.

FIGS. 11A, 11B, and 11C are block diagrams illustrating an example nanofibers fabrication process.

FIGS. 12A, 12B and 12C are block diagrams illustrating formation of a nanostructure according to an example embodiment.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural, logical and electrical changes may be made without departing from the scope of the present invention. The following description is, therefore, not to be taken in a limited sense, and the scope of the present invention is defined by the appended claims.

A microfluidic electrospray system is shown at 100 in FIG. 1. A microfluidic channel 110 is coupled at one end to a triangular tip 115, acting as a source for formation of nanofibers. Both are supported by a substrate 120. A reservoir 125 provides a polymer solution in one embodiment to the channel 110 and to the tip 115. Another end of the microfluidic channel 110 is coupled to a reservoir 125 formed in the substrate 120. The reservoir in one embodiment is coupled to a capillary tube 130, or other plumbing to provide the polymer solution to the reservoir and channel. A conductor, such as a gold wire 135 is coupled to the reservoir for coupling the reservoir to a power supply 137. The substrate is mounted on an x,y,z stage for moving the substrate laterally in a desired manner.

In one embodiment, the substrate 120 is positioned between approximately 5 mm to 12.5 mm from holder 145 on which a silicon substrate 150 with aluminum coating 155 is supported. The substrate and aluminum coating 155 are coupled to a ground via a conductor 160, forming a counter electrode. By applying a potential via power supply 137 with respect to the grounded substrate 150, a Taylor cone is established on tip 115, resulting in a liquid jet 170 being formed at the tip and moving toward the substrate 150. In one embodiment, the term Taylor cone is used to refer to any type of structure that result in a thin stream of liquid moving toward the substrate 150. By moving the substrate 120 by use of the x,y,z stage 140, the liquid jet moves across the substrate 150, creating nanofibers on the substrate.

The term “nanofibers” is meant to cover fibers within the dimensions described herein, and smaller fibers. Further the nanofibers may be larger than those described depending on multiple different parameters, including size of the triangle tip.

The microfluidic coupling allows new possibilities for materials processing and nanostructure formation. The source allows for smaller source to substrate distances and permits operation at lower voltages than conventional sources. The shorter distance, referred to as a deposition distance, enables greater control of nanofiber morphology and more localized deposition of the fibers. In one embodiment, nanofibers are formed within a 5 mm diameter circle on the substrate 150.

In one example, the electrospray device substrate 120 is attached on the x,y,z stage 140 and adjusted to form a deposition distance between the tip 115 and counter electrode/substrate of approximately 0.5 cm to 1.5 cm. A 300 nl/minute flow rate is created by coupling a syringe pump to the capillary tube 130. A potential is applied to the wire 135 of approximate 2000V to 8500V.

Approximately 500 nm of aluminum is optionally sputter-deposited on the silicon wafer and used as the counter electrode for nanofiber deposition. In one embodiment, the counter electrode is attached to a rotating optical chopper, with rotation rate varied between 40 RPM to 800 RPM. In a further embodiment, nanofibers are directly deposited on the silicon wafer without the need for the A1 layer. In this embodiment, the silicon wafer acts as the counter electrode.

Further detail of an electrospray device is shown at 200 in FIG. 2. In one embodiment, a top chip 210 has a microchannel 215 embossed therein. The device further comprises an emitter film 220, having a triangular or trapezoidal shaped tip 230. It should be noted that any type of source, such as commercially available electrospray sources may be used to provide an electrospray of desired materials in addition to the sources described herein. Electrospray techniques involve the use of an applied voltage to extract material from a surface.

In one embodiment, the emitter comprises a larger body portion that is rectangular, with the tip 230 extending from the rectangular portion. A bottom chip 240 is thermally bonded with the top chip 210, sandwiching a portion of the emitter film to hold it firmly between the chips. In one embodiment, the film covers a portion of the length of the channel at one end of the bonded chips as indicated at 250. The tip 230 extends laterally from the channel at end 250. A reservoir 260 is coupled to the other end of the channel 215.

The triangle tip 230 is approximately 3 um thick, and acts like a nozzle or wick that prevents liquid from spreading laterally at the exit of the fluidic channel. In one embodiment, the tip has an apex with an approximately 90 degree angle, and the angles adjacent the channel are approximately 45 degrees. The angle of the apex may be varied, such as between 40 and 120 degrees. At smaller apex angles, liquid may spread at the base of the triangle contacting the microchannel chip, as the wetting angle of solutions in the channel may be smaller than the angles the base of the triangle makes with the chip. Different apex angles may be optimal for solutions with different wetting angles. The base of the triangular tip is approximately 100 micrometers, and the height is approximately 50 micrometers. Thus, the base extends well beyond both sides of the channel when centered approximately at the center of the channel.

The shape of the tip 230 helps form and fix a position of a Taylor cone, as shown in FIG. 3. When a difference in potential is applied to the device, a liquid droplet with a critical curvature for establishing a Taylor cone is formed at the apex of the triangle. A liquid jet 320 is formed at the apex. Highly charged small liquid droplets are made extending toward the counter electrode. Excess electrostatic force extracts liquid from the apex of the Taylor cone to establish the liquid jet. Other shapes of emitter film may also be used, such as trapezoidal shaped emitter films. While an electrospray emitter is described as the source for nanofibers, other sources may also be used to create oriented nanofibers.

Polyethylene oxide was used as the nanofiber solution in one embodiment. It was prepared by dissolving PEO monomer (MW 100,000) at weight concentration of 6% to 10% in a mixture of 50% deionized water and 50% ethanol. Other concentrations may also be used. PEO polymeric solution is electrosprayed to the rotational counter electrode. The deposition distance is set at 2 cm and the position of the triangular tip was set at 2.0 cm laterally away from the center of the counter electrode. Other solutions may also be used to form nanofibers.

For a spinning process, a flow rate of 300 nl/minute is maintained with the syringe pump. 7000V was applied to the gold wire at the fluid source with the metalized substrate at ground potential. A Taylor cone is maintained at the apex of the triangle tip with a stable total ion current of 15 nA.

In various embodiments, nanofiber size and morphology depend on process parameters, which may be varied significantly. Such parameters include the deposition distance, applied electric field strength, and rotational speed of the counter electrode. At smaller deposition distances, the polymer may arrive at the counter electrode as a solution, resulting in a structure resembling a membrane with holes, rather than fibers. In one embodiment, the deposition distance is set to 0.75 cm, and a Taylor cone is established with 3500V applied to the gold electrode. This resulted in approximately 14.8 nA of total ion current and columnar nanofibers with an average diameter of 200 nm. Nanofibers appear to have partially dried while traveling to the counter electrode.

With a distance of approximately 1.0 cm, a Taylor cone is established at about 4000V, and an ion current of about 14.5 nA. Thinner nanofibers are formed in this case, with an average diameter of approximately 100 nm. With a distance of 1.5 cm, the Taylor cone is also established at 4000V, resulting in columnar nanofibers with an average diameter of approximately 100 nm.

From the above examples, the nanofiber size decreased from 200 nm to 100 nm while the deposition distance was increased from 0.5 cm to 1.0 cm. Extension of the deposition distance to more than 1.0 cm did not influence the nanofiber diameter. Once the fibers form in transit, the nanofiber size appears to be fixed, and the fibers are deposited on the surface as a solid.

Applied electric field strength was varied from 4000 V/cm to 8500 V/cm at a distance of 1.0 cm. At 4000 V/cm, cylindrical nanofibers are formed with an average diameter of 100 nm. At 5500 V/cm, the diameter is almost the same, but branched nanofibers with small diameter of 30 to 60 nm were fabricated between the main nanofibers. Nanospheres of approximately 200 to 400 nm were suspended between main nanofibers via smaller nanofibers. At 7000 V/cm, the diameter of the main nanofibers is about 120 nm. Small nanofibers between main nanofibers, as well as nanospheres increased further. At 8500 V/cm, the average diameter of the main nanofibers is about 150 nm. However, smaller, and a larger number nanofibers in the range of 10-20 nm formed. In addition, nanospheres with average diameter of 100 to 200 nm were suspended between medium size nanofibers via small nanofibers.

In still further embodiments, the substrate is rotated during fiber deposition. In various examples, the rotational speed of the counter electrode/substrate, was varied between 40 RPM and 800 RPM. The distance of the source was set approximately 2.0 cm from the center of the rotation of the electrode. At lower rotational speeds, nanofibers formed on the substrate tended to curve in a whiplike manner, creating loops and overlapping loops. As the speed is increased, the fibers formed tended to straighten out at approximately 600 RPM and higher, resulting in essentially straight or lateral fiber formation at nanoscales. The diameter of the nanofibers does not tend to be dependent on rotational speed at this distance.

FIG. 4 is a block perspective view of an electrospinning system 400 for creating polymer nanofibers on a spinning silicon substrate according to an embodiment of the invention. As in FIG. 1, substrate 120 is mounted on a xyz translation stage, and provides a liquid jet 170 from the apex of a triangle sandwiched about a microchannel 110. A syringe pump provides a polymer to the microchannel via tube 130. Conductor 135 is used to apply a potential. The translation stage is used to position the apex of the triangle a desired distance from a target substrate 410 and counter electrode 415, such as deposited aluminum on the substrate. The substrate and counter electrode are mounted on motor 420, such as an optical chopper motor for rotating the substrate with respect to the triangle emitter.

The substrate, in one embodiment, has features 425 formed on its surface, on which nanofibers are to be formed. Such features are shown as trenches at 510 in FIG. 5, formed using common processing techniques. Many other structures may be formed as desired. In one embodiment, the trenches 510 are formed with an orientation such that nanofibers 610 will be formed transverse to them as shown in a cross section in FIG. 6. In FIG. 6, the trenches 510 are heading into the page, while the nanofibers, represented at 610 are formed along the surface of the substrate 410 substantially perpendicular to the trenches. In one embodiment, the nanofibers form an angle with respect to the trenches that may be varied as desired. The width of the trenches may be varied as desired such that the nanofibers span and dip into the trenches, or span the trenches in a substantially straight line.

In one embodiment, different width trenches were used, with widths of approximately 3 um and 5 um with a depth of 2 um. The silicon counter electrode was spun by the motor to create a linear velocity of the counter electrode relative to the microfabricated electrospinning source that is varied between 0.0 cm/s to 168 cm/s.

In one example, the linear velocities were varied with a fixed deposition distance of 2.0 cm with an applied potential of 4000V for 10 to 20 seconds. As the surface velocity increases, the effect of random motion becomes less significant and the orientation of the fibers is dominated by the linear driven motion. If a consistent surface velocity is desired, the rotations per minute must be decreased as the nanofibers are applied further from the center of rotation. In one embodiment, linear velocities were varied between 0.0 cm/s and 168 cm/s for a PEO nanofiber solution. Nanofibers are substantially straight at approximately 126 cm/s. They may be straight at lower speeds, and are likely straight at higher speeds. While the diameter of the nanofibers does not change appreciably with distance from the source, the speed at which straight nanofibers are formed may vary with other parameters, such as applied potential.

In further embodiments, the substrate is not spun, but is moved in a linear direction at a desired speed by a translator or other device. In still further embodiments, the source is moved, or a combination of moving both the source and substrate are used to obtain the desired relative motion.

FIG. 7 shows two scanning electron microscope representations of an oriented nanofiber 710 with a diameter of about 150 nm fabricated over multiple 3 um wide trenches such as trench 720, and an oriented nanofiber 730 with a diameter of about 140 nm fabricated over multiple 5 um wide trenches such as trench 740. The fibers are suspended between tops of the trenches, and span the gap between the trenches in one embodiment. While trenches are shown as features formed on or in the substrate, many other different features, including feature extending out from the substrate surface may be formed, and have nanofibers deposited across the trenches. The metal layer, such as aluminum may be removed following deposition of the nanofibers using suitable selective etching techniques.

FIG. 8 is a block representation of a multi-tip electrospray emitter device. Four triangle emitters 810, 815, 820 and 825 are shown. Each emitter is coupled to a channel. They may be operated in parallel, or may be sequentially operated. When operated in parallel, the emitters are spaced sufficiently to minimize interference between the respective sprays. A multichannel system when operated in a multiplexed manner operates reliably with no significant cross contamination between the channels, forming substantially parallel sets of nanofibers.

In one embodiment, a “Y” shaped channel indicated at 900 in FIG. 9 is used to provide nanofibers producing fluid to a source. Channel 900 is used in one embodiment to mix PEO solution and Rhodamine B. A first branch 910 provides the PEO solution, and a second branch 920 provides Rhodamine B. The materials come together at a junction of the branches at 930 and begin mixing. The mixed solution is guided to a source, such as a triangular tip as described above by channel 940 for electrospinning to fabricate nanofibers. Other materials may also be used, and more than two branches are used if needed.

In one embodiment, a laminar flow is created in the channel 940 prior to reaching the source. Laminar flow may be used to create layered nanofibers. Additional functions, such as valves and other functions may be added in the channel to further manipulate and control the flow of nanofibers source materials. Reactions may also be facilitated by the channel and associated structures that may be formed. The use of such channels also facilitates the creation of arrays of sources.

FIGS. 10A, 10B, 10C, 10D, 10E and 10F are block schematic diagrams illustrating formation of a tip according to an example embodiment. Conventional microfabrication approaches may be used to form an electrospinning tip source or sources that may be dipped in a solution from which nanowires or nanofibers may be formed.

In FIG. 10A, a silicon wafer 1010 has silicon dioxide layers on both sides at 1015 and 1020. In one embodiment, SiO₂ layer 1015 is formed on top of wafer 1010 and is approximately 3 um thick. SiO₂ layer 1020 is formed on a bottom of the wafer 1010 and is approximately 1 um thick. In one embodiment, plasma enhanced chemical vapor deposition (PECVD) was used to form the oxide layers. Other thicknesses may be used as desired consistent with the formation of the tip.

A patterned photoresist 1025 is formed on the top or front of the wafer as shown in perspective view in FIG. 10B. A tip shape is defined in the photoresist as indicated at 1030. In one embodiment, the tip is in the shape of an arrow extending from a support structure, such as a rectangular block. The head of the arrow is a triangular shape coupled to the end of a shaft extending from the support structure. Other shapes of tips may be formed as described below.

FIG. 10C is a cross section of the wafer 1010 following etching of the oxide, such as by use of CHF₃/O₂ plasma. The remaining resist may be removed in an oxygen plasma. FIG. 10D is a cross section of the wafer 1010 following a full wafer etch-through to the lower oxide layer 1020, using a Bosch process, or other process that provides a fairly deep etch with desirable, fairly straight sidewall characteristics. Remaining oxide is then removed, such as by use of HF, and a conductive layer is applied to the top of the tip as seen at 1040 in FIG. 10E. The conductive layer in one embodiment is formed of approximately 20 mm of Cr and 100 nm of Au deposited by use of electron beam evaporation. Other conductors, thicknesses and methods of forming such may be used in various embodiments. Gold is used in one embodiment. The remaining silicon 1050 combined with the conductive layer form an electrospinning tip 1060, which may be removed from the wafer, which in one embodiment is a 4 inch wafer from which multiple tips may be formed. 25 tips may be formed in some embodiments, and cleaved from the wafer.

A perspective view of tip 1050 is seen in FIG. 10F, with the addition of a conductive wire 1070 attached to the conductive layer 1040 of tip 1050. In one embodiment, the wire 1070 comprises tungsten. Other conductive materials, such as gold, may also be used for the wire.

FIGS. 11A, 11B, and 11C are block schematic diagrams illustrating an example nanofibers fabrication process. An arrow tip 1110 is supported on a fixture to facilitate dipping the tip into a polymeric solution 1115 supported by a plate 1120. Plate 1120 may be made of glass or other suitable material that provides a surface to support the solution. Other solutions may be used that provide the ability to form nanowires/nanofibers. FIG. 11B illustrates dipping of the arrow tip 1110 into the solution 1115 generally at 1125. The arrow shape of the tip may help establish a droplet of solution localized on the tip.

In one example embodiment, for ease of observation of formation of a Taylor cone, the tip is placed approximately 2 cm from a rotating counter electrode 1130. The counter electrode is grounded in one embodiment, and a potential of approximately 4000 to 6000V is applied between the tip and the electrode as indicated at 1135 to form the Taylor cone. To minimize the effect of liquid evaporation from the droplet, the nanofiber fabrication process is done within a few seconds after droplet formation. For formation of aligned fibers, the counter electrode 1130 is coupled to a chopper motor 1140 to provide a simple means to control the motion of the tip relative the counter electrode 1130, which in one embodiment comprises a wafer. The velocity of the motor is adjusted to control the rotational velocity of the counter electrode.

In one embodiment, various solutions of PEO may be used. Weight concentrations of 5, 10, 20 and 30% of PEO in a solvent of 50% deionized water and 50% ethanol may be utilized. Other concentrations may also be used, as well as entirely different solutions that are capable of forming wires. For a composite particle deposition, a 50-50 mixture of 20% PEO polymer solution and a fluorescent latex nanosphere suspension may be prepared. A final approximated PEO polymer weight concentration in the prepared polymeric colloidal solutions is approximately 10%. The diameters of the fluorescent latex spheres are approximately 100 and 500 nm in one embodiment. The concentration of the spheres in one embodiment is between 9.0×10¹¹ and 7.0×10¹¹ particles per ml respectively. Other size spheres, and other types of spheres and particles may also be used.

Polyaniline (PANI) (48 mg, emeraldine base; Mw approximately 20,000, purchased from Aldrich, Wis., USA) may be dissolved in chloroform (1.5 ml) and doped with 10-camphorsulfonic acid (122 mg). PEO (48 mg, M_(w) approximately 900,000 purchased from Aldrich) may be added to the chloroform solution and stirred overnight. The concentration of PEO/PANI-HCSA may range from 0.5 to 2.0 wt. %. The amount of PEO mixed with PA may be varied from 10 to 80 wt. % in one embodiment.

In one embodiment, a Taylor cone is established with a potential of 4500 V applied to a 20 ul droplet and the counter electrode. Nanofibers may be generated for approximately 5 to 10 seconds. The length of the nanofiber is controlled by the volume of the droplet loaded on the tip. The length may also be controlled by controlling the potential. Removing the potential at desired times results in removing the Taylor cone, and hence stopping production of the nanofiber at a desired time and distance. Nanofibers are deposited immediately after the polymeric solution is loaded to reduce effects of evaporation. In addition to the arrow shaped tip, triangle-shaped and straight metal wire tips may be employed. It may be more difficult to establish a Taylor cone with some tip shapes.

Diameters of nanofibers deposited from the various solutions may be in the 100 to 200 nm range for the 5% solution, 200-300 nm range for 10%, 300-500 nm for 20% and 500 to 1800 nm range for 30%. The polymer viscosity increases with concentration. The viscosity of a 30% solution is very high. Lower viscosity solutions appear to result in smaller diameter fibers.

Deposition distance may also be varied. In one embodiment, the distance is varied between 0.5 to 1.5 cm with a PEO solution of 10%. The counter electrode is not spun in this embodiment. Changes may be observed in the nanofiber morphology. In the case of a 0.5 cm deposition distance, deposited polymer resembles a membrane. This may be the result of the short transit distance, in which the polymer may arrive at the counter electrode as a wet polymer, allowing them to merge to form larger fibers, or bond together to make a fibrous web. At a distance of 0.75 cm, cylindrical nanofibers may be formed of diameter 200 to 850 nm range. In this case, the nanofibers appear to have partially dried while traveling to the counter electrode. At 1.0 cm distances, thinner nanofibers appear to be created, having average diameters of approximately 153 nm. A 5% solution resulted in nanofibers as small as 45 nm.

In further embodiments, the motion of the tip relative to the counter electrode is used to control nanofiber orientation. A linear velocity of approximately less than approximately 168 cm per second produced slightly bent nanofibers, instead of fairly straight nanofibers. Higher linear velocities produced fairly straight nanofibers for a 10% solution. In further embodiments, the linear velocity used to produce substantially straight nanofibers may depend at least on the potential and solution used.

Composite materials may also be deposited by electrospraying a mixture of PEO and colloidal particles, such as the fluorescent nanospheres with 100 nm and 500 nm diameters. In one embodiment, such colloidal suspensions were spun with a relative tip to counter electrode velocity sufficient to provide straightened nanofibers with a 30 degree variation along the rotational direction, rather than a random orientation. Latex nanospheres may be confined in the nanofibers and are self assembled along the nanofibers. The diameter of the nanofibers may be in the 100 to 300 nm range, or other ranges depending on distance and percent solutions utilized. In one embodiment, a line density of nanospheres confined in the nanofibers is approximately 0.75 particles per um for 100 nm nanospheres, and approximately 0.68 particles per um for 500 nm nanospheres.

In one embodiment, the tips may be reused after surface cleaning. A wide range of polymeric material, such as highly viscous polymeric solutions can be electrospun from the tip. The short deposition distance as compared to syringe based electrospinning provides for easy control of the orientation of the nanofibers. The tips also provide the capability of electrospinning of colloidal suspensions mixed with a polymer solution to fabricate nanofibers composite materials. In addition to the formation of nanofibers, scanning tips may be used to electrospray liquids, chemicals and for particulate deposition on a surface.

In still further embodiments, a solution of poly(methyl methacrylate) (PMMA) is used for fiber formation. 4 wt. % and 5.5 wt. % PMMA solutions may be prepared by dissolving 67.2 mg and 92.4 mg of PMMA (Mw 495,000) in 2 ml of anisole (phenyl methyl ether), respectively. A pipette or other type of applicator may be utilized to provide 30 ul of solution on the silicon tip. A voltage of 4000 to 7000 V may be applied between the tip and counter electrode to establish the Taylor cone and extract a liquid jet from its apex. By rotating a target substrate on the counter electrode at approximately 500 rpm, the relative scanned motion of the counter electrode to the electrospinning source (the tip) controls orientation of the deposited PMMA nanofibers on the surface of the target substrate. A distance of approximately 1.5 cm between tip and target substrate was adequate to produce desired nanofibers.

Target substrates may include many different materials, such as silicon, aluminum, thin film aluminum on silicon, and non-conducting substrates, such as silicon dioxide, silicon nitride, glass slides, cover slips and others. Such non-conductive substrates are mounted on the counter electrode in the path of the extracted liquid jet.

With highly volatile solvents in the solution used to form a Taylor cone may be stable only for several seconds prior to evaporation. A side effect of such volatile solvents appears to be the formation of more than one polymer liquid jet being extracted from a silicon tip per deposition cycle. This may lead to fibers of different sizes being deposited on the same substrate. When multiple polymer jets are extracted, the diameters of such jets may have very small diameters. Reducing the size of the microfabricated tip may also consistently create nanofibers with very small diameters.

In one embodiment, using the 4 wt. % solution of PMMA in anisole, fibers were produced having an average diameter of approximately 85.2 nm. Fibers deposited using 4 wt. % solution of PMMA range from 81.4 to 326.5 nm with an average of 190 nm. Fibers deposited using 5.5 wt. % solution of PMMA range from 88.5 to 346 nm with an average of 206 nm.

The smallest diameter fibers extracted from the solutions were deposited when more than one polymer jet was extracted from the silicon tip. The multiple jets produced fibers of various sizes, instead of a single jet producing fibers of approximately the same size.

FIGS. 12A, 12B and 12C are block diagrams illustrating formation of a nanostructure according to an example embodiment. A PMMA nanofiber or mask 1210 is deposited on a substrate 1215, such as silicon. In one embodiment, the fiber 1210 is heated to 110° C. on a hot plate for 10 minutes to remove any remaining solvent. Other methods may be used to remove remaining solvent if desired. The substrate was then cooled and placed in a reactive ion etcher, where a CF₄ plasma chemistry was run for 1 minute to etch the underlying silicon substrate as seen in FIG. 12B, leaving a ridge 1220 of silicon beneath the fiber 1210. Etch selectivity of the PMMA mask 1210 to silicon substrate is 1.3 to 1 in one embodiment. The remaining PMMA mask 1210 may be removed in an oxygen plasma, leaving behind the ridge 1220 in FIG. 12C. In one embodiment, the ridge is a silicon structure with a width and height of 86.5 and 71.5 nm, respectively. Small variations in the width of the structure may be similar to those seen in structures defined by PMMA that were patterned by electron beam lithography. In further embodiments, different size structures may be created using wider or narrower nanofiber masks, along with variations of etching. Multiple nanofibers of various dimensions and orientations may be deposited, and even nanofiber meshes and random patterns may be used to crease a wide variety of etch masks. An x,y,z stepper may be used for moving the target substrate in desired manners during deposition of the nanofibers to provide even greater flexibility in mask pattern creation.

In another example embodiment of a nanostructure, a rounded channel has an elliptical cross section with major and minor radii of less than 100 nm. In one embodiment, a heat depolymerizable polycarbonate (HDPC) nanofiber is electrospun from a tip onto a substrate. A capping layer is formed on top of the substrate, and encapsulates the nanofiber. In one embodiment, the capping layer is silicon dioxide, selected for biocompatibility reasons.

The HDPC in one embodiment is a 20 wt. % solution of HDPC (M_(w)=100,000) in chlorobenzene. It is dispensed onto the silicon tip, and potential of approximately 6000 to 8000 volts is applied to form a Taylor cone and corresponding polymer jet. Target substrates include but are not limited to silicon, thin film silicon dioxide on silicon and glass. The substrate is mounted on the target electrode which is located approximately 1.5 cm from the source tip.

A photoresist is spun on the capping layer, and removed at two ends of the nanofiber by use of a photo mask or mechanically removed by wiping with a swab, wetted with acetone. The capping layer is then dry etched down to the substrate in a CHF₃/O₂ plasma chemistry to provide reservoirs for accessing the nanofiber. The remaining photoresist is removed in either an oxygen plasma or by using a solvent such as acetone. The substrate is then heated at 325° C. for approximately 24 hours or other suitable time to allow by-products of nanofiber polymer decomposition to diffuse out, forming a nanochannel from the depolymerized nanofiber, which effectively acts as a sacrificial layer.

Conventional silicon processing techniques utilize temperatures above the glass transition temperature, T_(g)=120° C., of HDPC. Processing the fibers above their T_(g) may cause the fibers to deform from their cylindrical shape, leading to corners in the resulting channels. Alternative, lower temperature processes include the use of silicon dioxide capping layer formed by evaporation over the fibers. Even though this does not require direct heating of the substrate, radiative heading from the silicon dioxide source may cause the channels to show similar heat induced characteristics, such as being flat on the bottom side that contacts the substrate.

Other materials with lower melting temperatures may also be evaporated or other wise formed on the substrate for use as a capping layer. Aluminum may also be used, resulting in a rounder channel, but still possibly slightly flat on the bottom. Aluminum may not be suitable for use where optical inspections of material in the channels is required, such as applications involving the use of fluorescently labeled biomaterials.

A further alternative capping layer uses spin-on glass. Use of this material results in a fairly elliptical shaped channel, with example major and minor diameters of 168 and 98 nm respectively. The spin-on glass may be dispensed on the surface of the substrate using a pipette, or other mechanism. The substrate is then spun at 1500 rpm for 60 seconds, baked on a hot plate at 70° C. for 5 minutes, then ramped to 250° C. in 15 minutes. This may result in substantially elliptical channels with minor diameters perpendicular to the surface of the substrate. With such elliptical shapes, the channel provides simple boundary conditions for finite element simulations of flow fields at a 100 nm length scale. Also, with no corners or acute angles, the channels may be useful for high resolution separation of biomaterials.

A scanned electrospinning technique has been described that may be used to form a variety of one dimensional nanostructures. It may enable rapid fabrication of oriented polymeric nanowires/nanofibers as well as their integration with lithographically defined surfaces. It also provides new opportunities for the manufacture of nanowires devices, including nanochannels of elliptical shape. 

The invention claimed is:
 1. A device for forming nanofibers on a substrate, the device comprising: a chip having at least one microchannel extending to an edge of the chip; an emitter film or films having one or more polygonal emitter tips coupled to the chip and to one or more respective microchannels such that the one or more polygonal tips extend from the edge of the chip; a fluid source coupled to the at least one microchannel; a counter electrode for supporting the substrate positioned a distance from the tip or tips of the emitter film or films; and conductors coupled to the counter electrode and the chip to apply a potential between the chip and the counter electrode, wherein the chip and the substrate are configured to move relative to one another while fluid is flowing to the one or more tips and the potential is applied to form laterally deposited nanofibers on the substrate.
 2. The device of claim 1 wherein the chip further comprises a plurality of merging channels coupled between the fluid source and the one or more microchannels.
 3. The device of claim 2 wherein the fluid source provides one or more fluids to the chip.
 4. The device of claim 3 wherein the merging channels merge at a junction.
 5. The device of claim 4 wherein the merging channels are adapted to provide for mixing of fluids.
 6. The device of claim 5 wherein the merging channels are adapted to provide for reaction of fluids that are mixed.
 7. The device of claim 1 wherein the emitter tips operate in a manner to form substantially parallel sets of straight nanofibers.
 8. The device of claim 1 and further comprising a valve operable to control the flow of fluid in the one or more microchannels.
 9. The device of claim 1 wherein the chip and substrate are adapted to create lateral movement between the substrate and the emitter to create nanofibers on the substrate. 